Container and method of manufacture

ABSTRACT

A method includes injection molding a preform using a two phase injection system having a first phase in which a material is injected into the preform and a second phase in which the material is injected into the preform. The preform is disposed in a mold. The preform is blow molded into an intermediate article. The intermediate article is trimmed to form a finished container. The first phase includes injecting a material into the preform to form a single layer of the preform and the second phase includes injecting the material to form inner and outer layers and an intermediate layer between the inner and outer layers. The inner and outer layers include the material and the intermediate layer includes at least one additive. Finished containers are disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/455,503, filed on Mar. 10, 2017, which claims the benefit of U.S.Provisional Patent Application No. 62/307,069, filed on Mar. 11, 2016.These applications are hereby incorporated herein by reference, in theirentireties.

TECHNICAL FIELD

The present disclosure generally relates to blow-molded containers andmore particularly to wide plastic containers and methods for making thesame for food and/or packaging, for example.

BACKGROUND

Plastic blow-molded containers are commonly used for food and/orbeverage packaging products. Many food and beverage products are sold tothe consuming public in blow-molded containers. These containers can bemade from polyethylene terephythalate or other suitable plastic resinsin a range of sizes. The empty blow-molded containers can be filled withfood and/or beverage products at a fill site utilizing automated fillequipment.

For example, manufacture of such plastic blow-molded containers caninclude initially forming plastic resin into a preform, which may beprovided by injection molding. Typically, the preform includes a mouthand a generally tubular body that terminates in a closed end. Prior tobeing formed into containers, preforms are softened and transferred intoa mold cavity configured in the shape of a selected container. In themold cavity, the preforms are blow-molded or stretch blow-molded andexpanded into the selected container.

Such plastic blow-molded containers may be produced on single stageinjection mold equipment. The single stage blow molding process combinesthe injection molding of the preform and blowing of the container intoone machine. This machine has an extruder that melts resin pellets andinjects the molten resin into a mold to create the preform. The preformis transferred to a blow station to form the container and removed fromthe machine. In some cases, the plastic blow-molded containers areproduced with two-stage equipment. The two-stage equipment makespreforms in an injection molding machine and then reheats and blows thepreforms into selected containers in a separate blowing machine. Thisdisclosure describes an improvement over these prior art technologies.

SUMMARY

In one embodiment, in accordance with the principles of the presentdisclosure, a method for manufacturing a container is provided. Themethod includes injection molding a preform using a two phase injectionsystem having a first phase in which a material is injected into thepreform and a second phase in which the material is injected into thepreform. The preform is disposed in a mold. The preform is blow moldedinto an intermediate article. The intermediate article is trimmed toform a finished container. The first phase includes injecting a materialinto the preform to form a single layer of the preform and the secondphase includes injecting the material to form inner and outer layers andan intermediate layer between the inner and outer layers. The inner andouter layers include the material and the intermediate layer includes atleast one additive. Finished containers are disclosed. In someembodiments, the inner, outer and intermediate layers each have anon-uniform thickness. In some embodiments, the inner, outer andintermediate layers each have an irregular thickness. In someembodiments, the intermediate layer comprises greater than 25% of a wallthickness of the finished container. In some embodiments, the at leastadditive is present in an amount between about 0.5 wt. % and about 5.0wt. % of the finished container. In some embodiments, the plurality oflayers comprises a third layer, the second layer being positionedbetween the first layer and the third layer, wherein the single layer,the first layer and the third layer each consist of the same materialand the single layer, the first layer and the third layer are free ofany additives. In some embodiments, the single layer and the inner andouter layers each consist of polyethylene terephythalate. In someembodiments, the at least additive comprises at least one of a groupconsisting of active oxygen scavengers, passive oxygen scavengers,colorants, calcium carbonate fillers, foaming agents, polymers, metals,compatibilizers, catalysts, and fatty acid salts

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more readily apparent from thespecific description accompanied by the following drawings, in which:

FIG. 1 is a side, cross section view of a component of one embodiment ofa container system in accordance with the principles of the presentdisclosure;

FIG. 1A is a side, cross section view of a component of one embodimentof a container system in accordance with the principles of the presentdisclosure;

FIG. 2 is a side view of a component of one embodiment of a containersystem in accordance with the principles of the present disclosure;

FIG. 3 is a side view of a component of one embodiment of a containersystem in accordance with the principles of the present disclosure;

FIG. 3A is a side, cross section view of one embodiment of a componentshown in FIG. 3;

FIG. 3B is a side, cross section view of one embodiment of a componentshown in FIG. 3;

FIG. 4 is a schematic view of a method of manufacturing a container inaccordance with the principles of the present disclosure;

FIG. 5 is a side, cross section view of a component of one embodiment ofa container system in accordance with the principles of the presentdisclosure;

FIG. 6 is a side, cross section view of a component of one embodiment ofa container system in accordance with the principles of the presentdisclosure;

FIG. 7 is a side, cross section view of one embodiment of a componentshown in FIG. 3 in accordance with the principles of the presentdisclosure;

FIG. 8 is a side, cross section view of one embodiment of a componentshown in FIG. 3 in accordance with the principles of the presentdisclosure;

FIG. 9 is a graph showing the relationship between the amount ofscavenger and the ability to inhibit oxygen ingress; and

FIG. 10 is a table showing weights of containers.

DETAILED DESCRIPTION

The exemplary embodiments of blow-molded containers and moreparticularly, polyethylene terephythalate (PET) containers and methodsfor making the same are discussed in terms of food packaging products.In some embodiments, the present container is manufactured via aninjection molded preform, which is subjected to a blow mold and trimprocess. In some embodiments, the present container can be filled withfood, food preparation oils, viscous and/or beverage products. In someembodiments, the present container can be employed as a cold fillcontainer. In some embodiments, the present container can be employed asa hot fill container. In some embodiments, the present container ismanufactured as a 22 ounce container filled with a non-dairy creamer. Insome embodiments, the present container is manufactured as a onekilogram container filled with a non-dairy creamer. In some embodiments,the present container is manufactured as a 60 ounce container filledwith peanut butter. In some embodiments, the present container isemployed as a light weight, high strength and barrier food packagingproduct.

In some embodiments, the present disclosure includes a container systemthat is employed with a method for manufacturing food packaging havingthe ability to produce food packages in a manner that minimizes the costof scrap material and/or allows the scrap material to be reused in otherapplications, such as, for example, the manufacturing of othercontainers that may be used for food packaging, for example, asdescribed herein.

In some embodiments, the present disclosure includes a method ofproducing a container wherein a barrier material is located in adiscrete layer of a first portion of a preform that is used to make thecontainer, while the discrete layer of barrier material is not presentin a second portion of the preform. In some embodiments, the discretelayer may include other materials in addition to the barrier material,such as, for example, polyethylene terephythalate (PET). In someembodiments, the second portion of the preform forms dome or moil scrapthat is trimmed from the first portion. In some embodiments, the firstportion forms a majority the finished container, while the secondportion forms only a small percentage of the finished container. In someembodiments, a majority of the second portion is trimmed from the firstportion so that most of the second portion may be used as scrap. In someembodiments, the entire second portion is trimmed from the first portionsuch that the entire second portion may be used as scrap. In someembodiments, the scrap is used to make other containers. That is, sincethe second portion does not include any additives, for example, thesection of the second portion that is trimmed off remains suitable foruse in making additional containers. Indeed, providing scrap materialthat is free of additives allows for full utilization of the scrapmaterial and avoids processing issues associated with reprocessing scrapmaterial that normally would contain additives and barrier materials.

In some embodiments, the present disclosure includes a method ofproducing a container wherein scrap material produced in manufacturingthe container is free of material additives, such as, for example,passive oxygen scavengers, active oxygen scavengers, colorants, calciumcarbonate fillers and foaming agents. In some embodiments, the additivesinclude one or more catalyst. These additives serve particular functionsin a PET bottle or container. In some embodiments, the scrap materialproduced in manufacturing the container is a dome or moil scrap that istrimmed from an intermediate article used to form the finishedcontainer. In blow and trim applications where a portion of the blowncontainer is removed from the final bottles (dome, moil, etc.) it isdesirable to not have these additives in the portion that is beingremoved. There are numerous reasons for not having these additives inthe removed portion of the bottle, such as, for example, cost savingsand reprocessing issues. Indeed, many of these additives are expensiveand it is desirable not to add extra cost into sections of the bottlethat will not be used in the marketplace. Moreover, these additives cancause considerable reuse issues in the grinding, drying and extrusionprocesses of the dome and moil. Processors want to be able toreintroduce this scrap material back into their processes so as not tolose the cost of the PET. In some embodiments, these additives can causeclarity issues, yellowing, varying color percentages and activation ofthe active oxygen scavengers when reintroduced in the process along withvirgin PET.

In blow and trim applications, the presence of additives in the preformcan also cause layer delamination issues at the trim point on thebottle. In some embodiments, the present disclosure avoids this bystopping the multi-layered preform material short of the trim point,which allows for a section of the blown bottle (primarily in the neckfinish and/or other portions) not to have the additive present. That is,the multi-layered portion of the preform that includes the additivesterminates below the trim point and a material that does not contain anyadditives extends from the multi-layered portion through the trim point,and at least in some cases, beyond the trim point. In the event that thetrim point is not a discrete line, the metal or plastic coveroverlapping the thread portion would act as a physical oxygen block andlittle to no loss in oxygen blocking would occur in this region. Thatis, the need for additives adjacent to the trim point is reduced oreliminated by the cover that overlaps the thread portion

In some embodiments, the present disclosure involves a two phaseinjection system. In a one phase of the two phase injection system, PETor virgin PET is injected into a preform. In another phase of the twophase injection system, the preform comprises multiple layers, at leastone of the multiple layers including an additive. That is, PET or virginPET and one or more selected additives are injected into the preform ina second injection cycle to form the multiple layers. In someembodiments, the phase in which the multiple layers are produced beginsafter the first phase is completed. This allows a dome or moil sectionof the blown bottle that is trimmed from a finished container and isultimately ground, blended, dried and added to the virgin PET meltstream to be free of additives which will prevent the problems discussedabove when the scrap is reused. In some embodiments, the term “virginPET” refers to a material that consists solely of PET. That is, virginPET does not include any additives, such as, for example, the additivesdiscussed above.

It is envisioned that the present disclosure may be useful formanufacturers that run multiple sizes of blow and trim bottles forvarious end uses. For example, the present disclosure may be useful toproduce containers for food items, such as, for example, dressings,sauces and peanuts, wherein oxygen permeation through the side walls ofthe container negatively affect shelf life and/or product flavor. It isenvisioned that the present disclosure may be useful to producecontainers for food items, such as, for example, non-dairy coffeecreamers that require color pigment for both fill-line concealment andproduct protection against UV light penetration. Other containers thatcan be made from the disclosed process include containers formayonnaise, salad dressings, peanuts as well as other condiments and/orfood products.

As shown in FIG. 10, the dome or moil section of the blown containerconstitutes 15%-40% of the total injected preform weight.

This material must be ground and reprocessed back into the system foreconomic considerations. Due to the high percentage of scrap material inthe blown containers, it is desirable to produce scrap material that isfree of any additives, such as, for example, the additives discussedabove, to avoid wasting expensive additives and/or avoid complicationsor costs involved in processing scrap material that includes additivesrelative to scrap material that does not include additives.

In some embodiments, the present manufacturing method includes the stepsof employing a single stage blow molding process and providing a preformthat produces containers having a dome. In some embodiments, the methodincludes injection molding the preform using a two phase injectionsystem, wherein one phase of the two phase injection system (e.g., afirst phase) comprises injecting material into the preform and anotherphase of the two phase injection system (e.g., a second phase) comprisesinjecting material into the preform to form multiple layers, at leastone of which includes an additive. The material used in the first phasedoes not include any additives. In some embodiments, the material usedin the first phase is virgin PET without additives and the material usedin the second phase is PET and additives. This allows the material thatis used in the first phase to be reground as virgin PET so as to avoidregrinding issues discussed above.

In some embodiments, the method includes the step of testing the one ormore preforms to ensure the one or more preforms include a selectedweight and selected neck finish dimension. In some embodiments, themethod includes the step of employing the one or more preforms with afour cavity production mold. In some embodiments, the method includesthe step of blow molding the one or more preforms, which may comprise acontainer. In some embodiments, the method includes the step of trimmingthe one or more blow-molded preforms. In some embodiments, the step oftrimming includes a spin trim operation to remove a dome from the one ormore blow-molded preforms. In some embodiments, the method includes atwo-stage blow molding process such that the one or more preforms areinjection molded and stored before blowing the one or more preforms toproduce a container. In some embodiments, the method includes reusingthe dome to produce other containers, such as, for example other widemouth containers. In some embodiments, reusing the dome includesgrinding, blending, drying and adding the dome and adding the ground,blended and dried material to a melt stream, wherein the done does notcontain additives.

In some embodiments, the present container is manufactured to include anoxygen scavenger and/or oxygen barrier material. That is, at least onelayer of a portion of the container that is not removed during themanufacturing process includes an oxygen scavenger and/or oxygen barriermaterial such that the oxygen scavenger and/or oxygen barrier materialis present in the finished container. In some embodiments, the containercomprises one or more layers having an oxygen barrier material. In someembodiments, the oxygen barrier material is present in the container inan amount between about 0.5 wt. % and about 5.0 wt. % of the container.In some embodiments, the oxygen barrier material is present in thecontainer in an amount about 2.0 wt. % of the container. In someembodiments, the oxygen barrier is a passive barrier and is unreactivewith oxygen. In some embodiments, the oxygen barrier is an oxygenscavenger and is reactive with oxygen to capture the oxygen. In someembodiments, the oxygen scavenger includes one or more oxygen barrier,such as, for example, one or more polymers, metals, compatibilizers,catalysts, and/or fatty acid salts.

In some embodiments, the container comprises one or more layers having ascavenger, such as, for example, an oxygen barrier material. In someembodiments, the scavenger is one or more of the additives discussedherein. In some embodiments, the scavenger is present in the containerin an amount between about 0.1 wt. % and about 20.0 wt. % of thecontainer. In some embodiments, the scavenger is present in thecontainer in an amount between about 0.1 wt. % and about 10.0 wt. % ofthe container. In some embodiments, the scavenger is present in thecontainer in an amount between about 0.1 wt. % and about 5.0 wt. % ofthe container. In some embodiments, the scavenger is present in thecontainer in an amount between about 1.0 wt. % and about 2.0 wt. % ofthe container. In some embodiments, the scavenger is present in thecontainer in an amount between about 2.0 wt. % and about 3.0 wt. % ofthe container. In some embodiments, the scavenger is present in thecontainer in an amount between about 4.0 wt. % and about 5.0 wt. % ofthe container. In some embodiments, the scavenger is present in thecontainer in an amount of about 1.4 wt. % of the container. In someembodiments, the scavenger is present in the container in an amount ofabout 2.8 wt. % of the container. In some embodiments, the scavenger ispresent in the container in an amount of about 4.2 wt. % of thecontainer. In some embodiments, the scavenger is present in thecontainer in an amount greater than about 5.0 wt. % of the container. Asshown in FIG. 9 and the table below, containers that include more of thescavenger inhibit oxygen ingress better than containers that includeless of the scavenger or no scavenger at all.

O2 Ingress Improvement Weight % Scavenger @ 150 Days 0 0 1.4 1.3 2.81.75 4.2 3.5

In some embodiments, the present manufacturing method provides PETenhancements via improved material orientation with selective physicalperformance features, such as, for example, improved top loadperformance, improved vacuum resistance performance and/or hoopstrength, improved O₂ performance, improved moisture vapor transmissionrate (MVTR) performance. In some embodiments, the enhancements includemodifications to the manufacturing process or the addition of additivesto provide a container made of PET that has a selected crystallinity, asdiscussed herein.

In some embodiments, the method is configured to produce a containerthat has a crystallinity of about 10%. In some embodiments, the methodis configured to produce a container that has a crystallinity betweenabout 15% and about 20%. In some embodiments, the preform is heated andstretched to produce a container having a crystallinity between about18% and about 30%. In some embodiments, the preform is heated andstretched to produce a container having a crystallinity between about20% and about 40%. In some embodiments, the preform includes a molecularweight between about 120,000 g/mol and about 240,000 g/mol. In someembodiments, the preform includes a molecular weight between about250,000 g/mol and about 450,000 g/mol. In some embodiments, the preformcomprises PET and has an axial stretch ratio of about 1.8 to 1 to about2.4 to 1.

The present disclosure may be understood more readily by reference tothe following detailed description of the embodiments taken inconnection with the accompanying drawing figures, which form a part ofthis disclosure. It is to be understood that this application is notlimited to the specific devices, methods, conditions or parametersdescribed and/or shown herein, and that the terminology used herein isfor the purpose of describing particular embodiments by way of exampleonly and is not intended to be limiting. Also, in some embodiments, asused in the specification and including the appended claims, thesingular forms “a,” “an,” and “the” include the plural, and reference toa particular numerical value includes at least that particular value,unless the context clearly dictates otherwise. Ranges may be expressedherein as from “about” or “approximately” one particular value and/or to“about” or “approximately” another particular value. When such a rangeis expressed, another embodiment includes from the one particular valueand/or to the other particular value. Similarly, when values areexpressed as approximations, by use of the antecedent “about,” it willbe understood that the particular value forms another embodiment. It isalso understood that all spatial references, such as, for example,horizontal, vertical, top, upper, lower, bottom, left and right, are forillustrative purposes only and can be varied within the scope of thedisclosure. For example, the references “upper” and “lower” are relativeand used only in the context to the other, and are not necessarily“superior” and “inferior”.

The following discussion includes a description of a container systemfor producing food packaging products, a container, related componentsand methods of manufacturing a container with an injection moldedpreform. Alternate embodiments are also disclosed. Reference is made indetail to the exemplary embodiments of the present disclosure, which areillustrated in the accompanying figures. Turning to FIGS. 1-11, thereare illustrated components of a container system and methods ofmanufacturing a container.

A finished PET blow-molded container 10, as shown in FIG. 3, isconstructed for use with a selected application, as described herein. Insome embodiments, finished container 10 is a wide-mouth container. Insome embodiments, the selected application includes food, foodpreparation oils, viscous and/or beverage products. In some embodiments,the selected application includes a 15 ounce container filled withmayonnaise. In some embodiments, the selected application includes a 30ounce container filled with mayonnaise. In some embodiments, theselected application includes a 16 ounce container filled with peanuts.In some embodiments, the selected application includes a 1 kilogramcontainer filled with non-dairy coffee creamer. In some embodiments, theselected application includes a 22 ounce container filled with non-dairycoffee creamer. In some embodiments, the selected application includes a22 ounce container filled with a non-dairy creamer. In some embodiments,the selected application includes a one kilogram container filled with anon-dairy creamer. In some embodiments, the selected applicationincludes a 60 ounce container filled with peanut butter. It isenvisioned that finished container 10 may include any size and shape andmay be filled with any type of food and/or beverage. In someembodiments, finished container 10 is configured for use forapplications that do not include foods and/or beverages.

In some embodiments, container 10 is manufactured with selected physicalperformance features, such as, for example, a 60 ounce PET containerhaving a body width of approximately 4.834 inches (in), a body depth ofapproximately 4.620 in, a neck diameter of 110 millimeters (mm), aweight of 96 grams (g), a T/L weight of 90 g, a vacuum average actual of2.107 inches of mercury (inHg) and a vacuum minimum actual of 1.100inHg.

In some embodiments, container 10 is manufactured with selected physicalperformance features, such as, for example, a 60 ounce PET containerhaving a body width of approximately 4.834 in, a body depth ofapproximately 4.620 in, a neck diameter of 110 mm, a weight of 96 g, aT/L weight of 68 g, a vacuum average actual of 1.562 inHg and a vacuumminimum actual of 1.210 inHg.

In some embodiments, container 10 is manufactured with selected physicalperformance features, such as, for example, a 22 ounce high-densitypolyethylene (HDPE) container having a body width of approximately 3.800in, a body depth of approximately 3.800 in, a neck diameter of 63 mm, aweight of 47 g, a T/L weight of 40 g, a top load minimum of 40pound-force (Lbf) and a top load target of 95 Lbf.

In some embodiments, container 10 is manufactured with selected physicalperformance features, such as, for example, a one kg HDPE containerhaving a body width of approximately 4.760 in, a body depth ofapproximately 4.760 in, a neck diameter of 63 mm, a weight of 77 g, aT/L weight of 60 g, a top load minimum of 90 Lbf and a top load targetof 115 Lbf.

In some embodiments, container 10 comprises a bottle or container. Insome embodiments, container 10 is used for food and/or beverage productpackaging. In some embodiments, container 10 comprises a cylindricalthreaded neck 12 wherein an outer diameter has a continuous thread 14.In some embodiments, thread 14 is in a range of about 53 mm to about 162mm. In some embodiments, container 10 is manufactured via a two-stagemethod, as described herein. In some embodiments, container 10 has anouter finish diameter in a range of about 53 mm to about 120 mm. In someembodiments, container 10 is manufactured via a single stage method, asdescribed herein. In some embodiments, container 10 has an outer finishdiameter of about 162 mm. Container 10 is produced as a lower part of anintermediate article 16, as shown in FIG. 2. In some embodiments,container 10 is formed by injection molding a preform 18 (e.g., FIGS.1-1C, 5 and 6) and then placing preform 18 into a cavity of a moldassembly, to be blown, as described herein.

In some embodiments, container 10 is manufactured via a two-stagemethod, as shown in FIG. 4. In some embodiments, an initial step S1includes injection molding preform 18 in an injection molding machineIJM during a first stage of the manufacturing operation. Preform 18 hasa thread forming surface 24 below a preform neck 26. In someembodiments, preform 18 has thread forming surface 24, which includes aportion of preform 18 below neck 26 that will press against moldassembly 22 to form neck 12 and thread 14. In some embodiments,container 10 may be manufactured with a snap fit portion, spiral threadsand/or a beaded rim. In some embodiments, preform 18 can be injectionmolded with a neck diameter smaller than the neck diameter of container10, such that a diameter of an opening 28 at a top of mold assembly 22is substantially reduced. As such, a plurality of mold cavities may beplaced in mold assembly 22 of a blow machine of the two-stage equipmentto provide improved production capacity. In some embodiments, container10 may be manufactured with a hoop stretch ratio in a range of about 1.6to 1 to about 2.0 to 1. In some embodiments, a step S2 includes removingpreform 18 from machine IJM.

In some embodiments, injection molding preform 18 comprises injectionmolding preform 18 using a two phase injection system, wherein a firstphase of the two phase injection system comprises injecting a material,such as for example, PET or virgin PET, into preform 18 and a secondphase of the two phase injection system comprises injecting materials,such as for example, PET or virgin PET and a barrier material oradditive, such as, for example, one or more passive oxygen scavengers,one or more active oxygen scavengers, one or more colorants, one or morecalcium carbonate fillers and/or one or more foaming agents into preform18. This results in a single layer of material (e.g., PET or virgin PET)forming a top portion 25 of preform 18 and material multiple layers ofmaterials forming a bottom portion 35 of preform 18.

In some embodiments, the single layer of top portion 25 consists of onematerial, such as, for example, PET or virgin PET. In some embodiments,the multiple layers of bottom portion 25 include a first layer 40 thatcomprises the same material that forms the single layer of top portion25, such as, for example, PET or virgin PET and a second layer 42 thatcomprises at least one additive, such as, for example, one or more ofthe additives discussed herein. In some embodiments, first layer 40consists of PET or virgin PET and second layer 42 consists of PET orvirgin PET and one or more of the additives discussed herein. In someembodiments, the single layer of top portion is free of any additives,such as, for example, the additives discussed herein. In someembodiments, layer 40 is free of any additives, such as, for example,the additives discussed herein. In some embodiments, layer 42 of preform18 consists of the at least one additive. That is, layer 42 of preform18 includes only the at least one additive. In some embodiments, layer42 of preform 18 includes the at least one additive and at least oneother material, such as, for example, PET. In some embodiments, layer 42of preform 18 comprises at least 20% or at least about 20% of a wallthickness of preform 18, wherein the wall thickness of preform 18 isdefined by the combined thicknesses of layer 40 and layer 42 of preform18. In some embodiments, layer 42 of preform 18 comprises at least 25%or at least about 25% of the wall thickness of preform 18. In someembodiments, layer 42 of preform 18 comprises at least 30% or at leastabout 30% of the wall thickness of preform 18. In some embodiments,layer 42 of preform 18 comprises at least 35% or at least about 35% ofthe wall thickness of preform 18. In some embodiments, layer 42 ofpreform 18 comprises at least 40% or at least about 40% of the wallthickness of preform 18. In some embodiments, layer 42 of preform 18comprises at least 45% or at least about 45% of the wall thickness ofpreform 18. In some embodiments, layer 42 of preform 18 comprises atleast 50% or at least about 50% of the wall thickness of preform 18. Insome embodiments, layer 42 of preform 18 comprises between 20% and 25%of the wall thickness of preform 18. In some embodiments, layer 42 ofpreform 18 comprises between 25% and 30% of the wall thickness ofpreform 18. In some embodiments, layer 42 of preform 18 comprisesbetween 30% and 35% of the wall thickness of preform 18. In someembodiments, layer 42 of preform 18 comprises between 35% and 40% of thewall thickness of preform 18. In some embodiments, layer 42 of preform18 comprises between 40% and 45% of the wall thickness of preform 18. Insome embodiments, layer 42 of preform 18 comprises between 45% and 50%of the wall thickness of preform 18. In some embodiments, layer 42 ofpreform 18 comprises between 50% and 55% of the wall thickness ofpreform 18.

As shown in FIG. 1, bottom portion 35 may include a third layer 44. Insome embodiments, layer 44 is free of any additives, such as, forexample, the additives discussed herein. In some embodiments, firstlayer 40 forms an outer surface of preform 18, third layer 44 forms aninner surface of preform 18 and second layer 42 is positioned betweenfirst layer 40 and third layer 44. In some embodiments, first layer 40and third layer 44 comprise the same material, such as, for example, PETor virgin PET and second layer 42 comprises a material, such as, forexample, PET or virgin PET and one or more additive, such as, forexample, one or more of the additives discussed herein. In someembodiments, first layer 40 and third layer 44 consist of a singlematerial, such as, for example, PET or virgin PET and second layer 42comprises a material, such as, for example, PET or virgin PET and one ormore additive, such as, for example, one or more of the additivesdiscussed herein. In some embodiments, layers 40, 44 are free of anyadditives, such as, for example, the additives discussed herein, andsecond layer 42 comprises one or more additives, such as, for example,one or more of the additives discussed herein. In some embodiments, theone or more additives are evenly dispersed throughout layer 42. In someembodiments, the one or more additives are randomly dispersed in layer42. In some embodiments, an inner portion of layer 42 comprises more ofthe one or more additives than an outer portion of layer 42. In someembodiments, the outer portion of layer 42 comprises more of the one ormore additives than the inner portion of layer 42.

In some embodiments, layer 42 of preform 18 consists of the at least oneadditive. That is, layer 42 of preform 18 includes only the at least oneadditive. In some embodiments, layer 42 of preform 18 includes the atleast one additive and at least one other material, such as, forexample, PET. In some embodiments, layer 42 of preform 18 comprises atleast 20% or at least about 20% of a wall thickness of preform 18,wherein the wall thickness of preform 18 is defined by the combinedthicknesses of layer 40, layer 42 and layer 44 of preform 18. In someembodiments, layer 42 of preform 18 comprises at least 25% or at leastabout 25% of the wall thickness of preform 18. In some embodiments,layer 42 of preform 18 comprises at least 30% or at least about 30% ofthe wall thickness of preform 18. In some embodiments, layer 42 ofpreform 18 comprises at least 35% or at least about 35% of the wallthickness of preform 18. In some embodiments, layer 42 of preform 18comprises at least 40% or at least about 40% of the wall thickness ofpreform 18. In some embodiments, layer 42 of preform 18 comprises atleast 45% or at least about 45% of the wall thickness of preform 18. Insome embodiments, layer 42 of preform 18 comprises at least 50% or atleast about 50% of the wall thickness of preform 18. In someembodiments, layer 42 of preform 18 comprises between 20% and 25% of thewall thickness of preform 18. In some embodiments, layer 42 of preform18 comprises between 25% and 30% of the wall thickness of preform 18. Insome embodiments, layer 42 of preform 18 comprises between 30% and 35%of the wall thickness of preform 18. In some embodiments, layer 42 ofpreform 18 comprises between 35% and 40% of the wall thickness ofpreform 18. In some embodiments, layer 42 of preform 18 comprisesbetween 40% and 45% of the wall thickness of preform 18. In someembodiments, layer 42 of preform 18 comprises between 45% and 50% of thewall thickness of preform 18. In some embodiments, layer 42 of preform18 comprises between 50% and 55% of the wall thickness of preform 18. Insome embodiments, layer 42 of preform 18 comprises greater than 55% ofthe wall thickness of preform 18.

In some embodiments, preform 18 does not include a sprue when preform 18is introduced into the molding process. It is envisioned that preform 18may be formed without using a sprue or that preform 18 may be formedusing a sprue, wherein the sprue is severed or otherwise removed frompreform 18 prior subjecting preform 18 to the molding process. As such,layer 42 is maintained between layers 40 and 44 such that no portion oflayer 40 extends through layer 40 or layer 44 when preform 18 ispositioned within the mold, as described herein. In this configuration,layer 40 defines the outermost surface of bottom portion 35 along theentire length of bottom portion 35. Furthermore, bottom portion 35 hasan arcuate portion between the sidewalls, wherein the arcuate portion iscontinuously curved between the sidewalls, as shown in FIGS. 1-1C, 5 and6. That is, the arcuate portion is continuously curved from one of thesidewalls to the other one of the sidewalls when preform 18 ispositioned within the mold, as described herein. In some embodiments,the arcuate portion has a continuous radius of curvature from one of thesidewalls to the other one of the sidewalls when preform 18 ispositioned within the mold, as described herein.

During the molding process, layers 40, 42, 44 are maintained such thatlayers 40, 42, 44 are also present in finished container 10, as shown inFIGS. 3A and 3B. It has been found that the configuration of layers 40,42, 44 discussed above makes the one or more additives in second layer42 function more effectively that if the one or more additives weredispersed in each of layers 40, 42, 44. For example, when the one ormore additive in second layer 42 is an oxygen scavenger, such as, forexample, one or more of the oxygen scavengers discussed herein, theoxygen scavenger decreases the level of oxygen in container 10 moreeffectively than if the oxygen scavenger was also included in layers 40,44. This will prevent or reduce the amount of oxygen that will be ableto enter the inside 15 of container 10, hence extending the shelf lifeof any food and/or beverage product within container 10. Indeed, theconfiguration of layers 40, 42, 44 discussed above allows layer 42 toform a barrier that prevents or reduces the ability of oxygen to movefrom the environment surrounding container 10 to the inside 15 ofcontainer 10.

In some embodiments, layer 42 of container 10 consists of the at leastone additive. That is, layer 42 of container 10 includes only the atleast one additive. In some embodiments, layer 42 of container 10includes the at least one additive and at least one other material, suchas, for example, PET. In some embodiments, layer 42 of container 10comprises at least 20% or at least about 20% of a wall thickness ofcontainer 10, wherein the wall thickness of container 10 is defined bythe combined thicknesses of layer 40, layer 42 and layer 44 of container10. In some embodiments, layer 42 of container 10 comprises at least 25%or at least about 25% of the wall thickness of container 10. In someembodiments, layer 42 of container 10 comprises at least 30% or at leastabout 30% of the wall thickness of container 10. In some embodiments,layer 42 of container 10 comprises at least 35% or at least about 35% ofthe wall thickness of container 10. In some embodiments, layer 42 ofcontainer 10 comprises at least 40% or at least about 40% of the wallthickness of container 10. In some embodiments, layer 42 of container 10comprises at least 45% or at least about 45% of the wall thickness ofcontainer 10. In some embodiments, layer 42 of container 10 comprises atleast 50% or at least about 50% of the wall thickness of container 10.In some embodiments, layer 42 of container 10 comprises between 20% and25% of the wall thickness of container 10. In some embodiments, layer 42of container 10 comprises between 25% and 30% of the wall thickness ofcontainer 10. In some embodiments, layer 42 of container 10 comprisesbetween 30% and 35% of the wall thickness of container 10. In someembodiments, layer 42 of container 10 comprises between 35% and 40% ofthe wall thickness of container 10. In some embodiments, layer 42 ofcontainer 10 comprises between 40% and 45% of the wall thickness ofcontainer 10. In some embodiments, layer 42 of container 10 comprisesbetween 45% and 50% of the wall thickness of container 10. In someembodiments, layer 42 of container 10 comprises between 50% and 55% ofthe wall thickness of container 10.

In some embodiments, layers 40, 42, 44 have different thicknesses, asshown in FIG. 5. In some embodiments, at least one of layers 40, 42, 44has an irregular thickness. That is, the thickness of at least one oflayers 40, 42, 44 varies along all or a portion of bottom portion 35. Insome embodiments, at least one of layers 40, 42, 44 has an undulatingthickness. It is contemplated that preform 18 in the embodiment shownFIG. 5 may be formed by injecting a first material into a mold to formlayer 40 or layer 44. A second material is then injected into the moldto form layer 42. After layer 42 is formed, the first material isinjected into the mold to form the other one of layer 40 and layer 44.In some embodiments, the first material comprises of PET or virgin PETand the second material consists of PET or virgin PET and at least oneadditive, such as, for example, one or more of the additives discussedherein. In some embodiments, the first material is free of anyadditives, such as, for example, the additives discussed herein. In someembodiments, the first material consists of PET or virgin PET and thesecond material consists of PET or virgin PET and at least one additive,such as, for example, one or more of the additives discussed herein. Insome embodiments, the one or more additives include an active oxygenscavenger, such as, for example, the oxygen scavengers discussed herein.In some embodiments, the one or more additives include a passive oxygenscavenger, such as, for example, nylon. In some embodiments, the one ormore additives include active and passive oxygen scavengers.

In some embodiments, the single layer of top portion 25 has the samethickness in container 10 as the combined thickness of layers 40, 42,44. In some embodiments, layers 40, 42, 44 each have the same thicknessin container 10. In some embodiments, at least one of layers 40, 42, 44in container 10 has a thickness that is greater than a thickness ofanother one of layers 40, 42, 44 in container 10. In some embodiments,at least one of layers 40, 42, 44 in container 10 has a thickness thatis less than a thickness of another one of layers 40, 42, 44 incontainer 10. In some embodiments, layers 40, 44 each have the samethickness in container 10 and layer 42 has a thickness in container 10that is different than the thicknesses of layers 40, 44. In someembodiments, layers 40, 44 each have the same thickness in container 10and layer 42 has a thickness in container 10 that is greater than thethicknesses of layers 40, 44 in container 10. In some embodiments,layers 40, 44 each have the same thickness in container 10 and layer 42has a thickness that is less than the thicknesses of layers 40, 44 incontainer 10.

In some embodiments, at least one of layers 40, 42, 44 in container 10comprises strength hardened PET. In some embodiments, each of layers 40,42, 44 in container 10 comprises strength hardened PET. In someembodiments, layer 42 comprises strength hardened PET in container 10and layers 40, 44 do not. In some embodiments, at least one of layers40, 44 comprise strength hardened PET in container 10 and layer 42 doesnot.

In one embodiment, shown in FIG. 1A, the multiple layers of bottomportion 25 include a first layer 46, a second layer 48, a third layer50, a fourth layer 52 and a fifth layer 54. First layer 46 forms anouter surface of preform 18 and fifth layer 54 forms an opposite innersurface of preform 18. In some embodiments, layers 46, 50, 54 eachcomprise the same material that forms the single layer of top portion25, such as, for example, PET or virgin PET and layers 48, 52 eachcomprise at least one additive, such as, for example, one or more of theadditives discussed herein. In some embodiments, layers 46, 50, 54 eachconsist of PET or virgin PET and layers 48, 52 each consist of PET orvirgin PET and one or more of the additives discussed herein. In someembodiments, layers 46, 50, 54 are free of any additives, such as, forexample, the additives discussed herein.

In some embodiments, layers 46, 50, 54 each comprise the same material,such as, for example, PET or virgin PET and layers 48, 52 each comprisea material, such as, for example, PET or virgin PET and one or moreadditive, such as, for example, one or more of the additives discussedherein. In some embodiments, layers 46, 50, 54 each consist of a singlematerial, such as, for example, PET or virgin PET and layers 48, 52 eachcomprise a material, such as, for example, PET or virgin PET and one ormore additive, such as, for example, one or more of the additivesdiscussed herein. In some embodiments, the one or more additives areevenly dispersed throughout layers 48, 52. In some embodiments, the oneor more additives are randomly dispersed in layers 48, 52. In someembodiments, inner portions of layers 48, 52 comprise more of the one ormore additives than outer portions of layers 48, 52. In someembodiments, the outer portions of layers 48, 52 comprise more of theone or more additives than the inner portions of layer layers 48, 52. Insome embodiments, layers 48, 52 comprise the same additives. In someembodiment, layer 48 comprises at least one additive, such as forexample, one or more of the additives discussed herein, that isdifferent from the additive or additives layer 52 comprises, whereinlayer 52 comprises one or more of the additives discussed herein.

In some embodiments, layers 48, 52 of preform 18 each consist of the atleast one additive. That is, layers 48, 52 of preform 18 each includeonly the at least one additive. In some embodiments, layers 48, 52 ofpreform 18 comprise at least 20% or at least about 20% of a wallthickness of preform 18, wherein the wall thickness of preform 18 isdefined by the combined thicknesses of layer 46, layer 48, layer 50,layer 52 and layer 54 of preform 18. In some embodiments, layers 48, 52of preform 18 comprise at least 25% or at least about 25% of the wallthickness of preform 18. In some embodiments, layers 48, 52 of preform18 comprise at least 30% or at least about 30% of the wall thickness ofpreform 18. In some embodiments, layers 48, 52 of preform 18 comprise atleast 35% or at least about 35% of the wall thickness of preform 18. Insome embodiments, layers 48, 52 of preform 18 comprise at least 40% orat least about 40% of the wall thickness of preform 18. In someembodiments, layers 48, 52 of preform 18 comprise at least 45% or atleast about 45% of the wall thickness of preform 18. In someembodiments, layers 48, 52 of preform 18 comprise at least 50% or atleast about 50% of the wall thickness of preform 18. In someembodiments, layers 48, 52 of preform 18 comprise between 20% and 25% ofthe wall thickness of preform 18. In some embodiments, layers 48, 52 ofpreform 18 comprise between 25% and 30% of the wall thickness of preform18. In some embodiments, layers 48, 52 of preform 18 comprise between30% and 35% of the wall thickness of preform 18. In some embodiments,layers 48, 52 of preform 18 comprise between 35% and 40% of the wallthickness of preform 18. In some embodiments, layers 48, 52 of preform18 comprise between 40% and 45% of the wall thickness of preform 18. Insome embodiments, layers 48, 52 of preform 18 comprise between 45% and50% of the wall thickness of preform 18. In some embodiments, layers 48,52 of preform 18 comprise between 50% and 55% of the wall thickness ofpreform 18. In some embodiments, layers 48, 52 of preform 18 comprisegreater than 55% of the wall thickness of preform 18.

During the molding process, layers 46, 48, 50, 52, 54 are maintainedsuch that layers 46, 48, 50, 52, 54 are also present in finishedcontainer 10, as shown in FIG. 3B. It is envisioned the configuration oflayers 46, 48, 50, 52, 54 discussed above makes the one or moreadditives in layers 48, 52 function more effectively that if the one ormore additives were dispersed in each of layers 46, 48, 50, 52, 54. Forexample, when the one or more additive in layers 48, 52 is an oxygenscavenger, such as, for example, one or more of the oxygen scavengersdiscussed herein, the oxygen scavenger decreases the level of oxygen incontainer 10 more effectively than if the oxygen scavenger was alsoincluded in layers 46, 50, 54. This will prevent or reduce the amount ofoxygen that will be able to enter the inside 15 of finished container,hence extending the shelf life of any food and/or beverage productwithin finished container 10. Indeed, the configuration of layers 46,48, 50, 52, 54 discussed above allows layers 48, 52 to form barriersthat prevent or reduce the ability of oxygen to move from theenvironment surrounding container 10 to the inside 15 of container 10.

In some embodiments, layers 48, 52 each consist of the at least oneadditive. That is, layers 48, 52 of container 10 each include only theat least one additive. In some embodiments, layers 48, 52 of container10 comprise at least 20% or at least about 20% of a wall thickness ofcontainer 10, wherein the wall thickness of container 10 is defined bythe combined thicknesses of layer 46, layer 48, layer 50, layer 52 andlayer 54 of container 10. In some embodiments, layers 48, 52 ofcontainer 10 comprise at least 25% or at least about 25% of the wallthickness of container 10. In some embodiments, layers 48, 52 ofcontainer 10 comprise at least 30% or at least about 30% of the wallthickness of container 10. In some embodiments, layers 48, 52 ofcontainer 10 comprise at least 35% or at least about 35% of the wallthickness of container 10. In some embodiments, layers 48, 52 ofcontainer 10 comprise at least 40% or at least about 40% of the wallthickness of container 10. In some embodiments, layers 48, 52 ofcontainer 10 comprise at least 45% or at least about 45% of the wallthickness of container 10. In some embodiments, layers 48, 52 ofcontainer 10 comprise at least 50% or at least about 50% of the wallthickness of container 10. In some embodiments, layers 48, 52 ofcontainer 10 comprise between 20% and 25% of the wall thickness ofcontainer 10. In some embodiments, layers 48, 52 of container 10comprise between 25% and 30% of the wall thickness of container 10. Insome embodiments, layers 48, 52 of container 10 comprise between 30% and35% of the wall thickness of container 10. In some embodiments, layers48, 52 of container 10 comprise between 35% and 40% of the wallthickness of container 10. In some embodiments, layers 48, 52 ofcontainer 10 comprise between 40% and 45% of the wall thickness ofcontainer 10. In some embodiments, layers 48, 52 of container 10comprise between 45% and 50% of the wall thickness of container 10. Insome embodiments, layers 48, 52 of container 10 comprise between 50% and55% of the wall thickness of container 10.

In some embodiments, the single layer of top portion 25 has the samethickness as the combined thickness of layers 46, 48, 50, 52, 54. Insome embodiments, layers 46, 48, 50, 52, 54 each have the samethickness. In some embodiments, at least one of layers 46, 48, 50, 52,54 has a thickness that is greater than a thickness of another one oflayers 46, 48, 50, 52, 54. In some embodiments, at least one of layers46, 48, 50, 52, 54 has a thickness that is less than a thickness ofanother one of layers 46, 48, 50, 52, 54. In some embodiments, layers46, 50, 54 each have the same thickness and layers 48, 52 each have athickness that is different than the thicknesses of layers 46, 50, 54.In some embodiments, layers 46, 50, 52 each have the same thickness andat least one of layers 48, 52 has a thickness that is greater than thethicknesses of layers 40, 44. In some embodiments, layers 46, 50, 52each have the same thickness and at least one of layers 48, 52 has athickness that is less than the thicknesses of layers 40, 44. In someembodiments, layers 48, 52 each have the same thickness. In someembodiments, layers 48, 52 have different thicknesses.

In some embodiments, at least one of layers 46, 48, 50, 52, 54 incontainer 10 comprises strength hardened PET. In some embodiments, eachof layers 46, 48, 50, 52, 54 in container 10 comprises strength hardenedPET. In some embodiments, at least one of layers 40, 44 comprisesstrength hardened PET in container 10 and layers 46, 50, 54 do not. Insome embodiments, at least one of layers 46, 50, 54 comprise strengthhardened PET in container 10 and layers 40, 44 do not.

In some embodiments, the two-stage method includes one or more steps ina second stage of the manufacturing operation. For example, in a step S3of the second stage, preform 18 is provided having a dome formingsurface 30, thread forming surface 24 and a body forming surface 32. Insome embodiments, the second stage includes a step S4, which comprisespre-heating preform 18 to a temperature in a range of about 95 degreesCelsius (C) to about 110 degrees C. In some embodiments, dome formingsurface 30 is formed solely from a material, such as, for example, PETor virgin PET. In some embodiments, dome forming surface 30 is free ofany additives, such as, for example, the additives discussed herein. Insome embodiments, dome forming surface 30 includes a single layer isformed solely from a material, such as, for example, PET or virgin PET.That is, thread forming surface 24 is free any additives, such as, forexample, the additives discussed herein. In some embodiments, threadforming surface 24 includes layers, such as, for example, layers 40, 42,44 or layers 46, 48, 50, 52, 54 and is formed from a material, such as,for example, PET or virgin PET, and one or more additive, such as, forexample, one or more of the additives discussed herein. In someembodiments, body forming surface 32 includes layers, such as, forexample, layers 40, 42, 44 or layers 46, 48, 50, 52, 54 and is formedfrom a material, such as, for example, PET or virgin PET, and one ormore additive, such as, for example, one or more of the additivesdiscussed herein. In some embodiments, the multi-layered portion ofpreform 18 that includes the additives (the portion that includes layers40, 42, 44 or layers 46, 48, 50, 52, 54) terminates below the trimpoint, as discussed herein, and that the portion of above the trim pointincludes a single layer that is free of any additives, such as, forexample, the additives discussed herein.

In some embodiments, the second stage includes a step S5, whichcomprises mounting pre-heated preform 18 in place within cavity 20 ofmold assembly 22. Mold assembly 22 has an interior mold surface shapedto correspond to the selected configuration of container 10. Asdiscussed above, the interior mold surface can be shaped such thatcontainer 10 has any size and/or shape, depending upon the application.In some embodiments, the temperature of mold assembly 22 is in a rangeof about 40 degrees Fahrenheit (F) to about 110 degrees F. Preform 18has a flange 34, which mounts on mold assembly 22 adjacent opening 28.Preform 18 has surface 30 that forms dome 36 of intermediate article 16,surface 24 that forms neck 12 of intermediate article 16 and surface 32,which forms body 38 of intermediate article 16. In some embodiments,surface 30 has a wall thickness in a range of about 0.100 inches (in) toabout 0.200 in. In some embodiments, surface 24 has a wall thickness ina range of about 0.100 in to about 0.200 in. In some embodiments,surface 32 has a wall thickness in a range of about 0.100 in to about0.200 in.

A step S6 includes blowing air into preform 18 to mold intermediatearticle 16, as shown in FIG. 4. In some embodiments, air is blown from adryer and at a pressure in a range of about 35 to about 40 bar blowninto an open end 40 of preform 18 to stretch or extend surfaces 30, 24,32 and a bottom surface 42 of preform 18 radially outwardly and axiallydownwardly against the interior molding surface of mold assembly 22, asshown in FIG. 3. A step S7 includes removing intermediate article 16from mold assembly 22.

In some embodiments, preform 18 has a diameter of about 3.3 inchesadjacent surface 24 and a length of about 6.2 inches; and intermediatearticle 16 has a diameter of about 6 inches and a length of about 10.3inches. In some embodiments, finished container 10, after trimming ofintermediate article 16 as described herein, has a maximum diameter ofabout 7.25 inches.

In some embodiments, dome 36 is attached to an upper edge of neck 12along an annular recess 44. In some embodiments, the second stageincludes a step S8, which comprises removing and/or trimming off dome 36from intermediate article 16 adjacent neck 12 with a trimming machineTM. Dome 36 is severed from intermediate article 16 to produce finishedcontainer 10, as shown in FIG. 3. As such, the second stage includes astep S9 of providing finished container 10.

As discussed above, the multi-layered portion of preform 18 thatincludes the additives (the portion that includes layers 40, 42, 44 orlayers 46, 48, 50, 52, 54) terminates below the trim point and that theportion of above the trim point includes a single layer that is free ofany additives, such as, for example, the additives discussed herein. Inthat dome 36 is formed from the single layer of top portion 25 ofpreform that does not include any additives, dome 36 is free of any ofthe additives discussed above. In some embodiments, dome 36 is scrapmaterial that may be reused in another manufacturing process, such as,for example, the manufacturing of another container, such as, forexample, another container that is the same or similar to container 10.

Dome 36 may be ground, blended, dried and added to a melt stream toproduce a second preform. In some embodiments the melt stream includesvirgin PET without any other additives. In some embodiments the meltstream includes PET in addition to one or more of the additivesdiscussed above. In some embodiments the melt stream includes virgin PETwithout any other additives and one or more of the additives discussedabove is added to the melt stream after ground, blended and dried dome36 is added to the melt stream. The second preform is disposed in amold, similar to step S3 discussed above. The second preform may then bepre-heated, similar to step S4 discussed above. In some embodiments, thepreheated second preform is mounted in place within a cavity of a mold,such as, for example, cavity 20 of mold assembly 22, similar to step S5discussed above. In some embodiments, the second preform is air blown tomold a second intermediate article similar to intermediate article 16,similar to step S6 discussed above. The second intermediate article isremoved from the mold assembly, similar to step S7 discussed above. Insome embodiments, a dome of the second intermediate article, similar todome 36, is removed and/or trimmed off from the second intermediatearticle adjacent a neck of the second intermediate article that issimilar to neck 12 with a trimming machine, such as, for exampletrimming machine TM. The dome of the second intermediate article issevered from the second intermediate article to produce a secondfinished container that is similar to finished container 10.

In some embodiments, the first container 10 and/or the second finishedcontainer, as described herein, can be fabricated from materialssuitable for food packaging products. In some embodiments, suchmaterials include synthetic polymers such as thermoplastics, semi-rigidand rigid materials, elastomers, fabric and/or their composites.

In some embodiments, container 10 comprises PET and the method of makingcontainer 10 discussed above may be modified to, for example, vary thecrystallinity of PET. In some embodiments, the method is configured toprevent crystallization such that the PET is amorphous. Such embodimentsmay be used in applications where it is desired that container 10 beclear and/or container 10 is not expected to encounter elevatedtemperatures or aggressive chemical environments. In some embodiments,the temperature that preform 18 is exposed to during the molding processmay be limited such that the temperature does not exceed a selectedthreshold temperature to produce container 10 wherein the PET isamorphous. In some embodiments, the selected threshold temperature isabove the glass-transition temperature of PET, but below thecrystallization temperature of PET.

In some embodiments, it may be desired that the PET be semi-crystallineor crystalline. Such embodiments may be used in applications where itacceptable that container 10 has at least some degree of cloudinessand/or applications where it is desired that the PET be reinforced toprovide added strength. It is envisioned that having container 10include semi-crystalline or crystalline PET may be useful forapplications wherein container 10 may encounter elevated temperatures oraggressive chemical environments. In some embodiments, glass fibersand/or mineral fillers are added to provide make the PETsemi-crystalline or crystalline. In some embodiments, the temperaturethat preform 18 is exposed to during the molding process may be requiredto exceed a selected threshold temperature wherein the PET is notquenched rapidly to produce container 10 wherein the PET issemi-crystalline or crystalline. In some embodiments, the selectedthreshold temperature is above the crystallization temperature of PET.In some embodiments, the selected threshold temperature is below themelting temperature of PET. In some embodiments, the amount of timepreform 18 is exposed to the selected temperature may be varied toachieve the desired amount of crystallinity. In some embodiments,preform 18 is stretched in place of or in addition to heating preform 18during the molding process to exceed the selected temperature. In someembodiments, the PET used has a narrow molecular weight, linear polymerchain structure, and high molecular weight to make the PETsemi-crystalline or crystalline. In some embodiments, nucleating agentsare added to produce container 10 wherein the PET is semi-crystalline orcrystalline. In some embodiments, the nucleating agents include, forexample, talc, sodium benzoate and an ionomer. In some embodiments,pressure may be applied during the molding process to produce container10 wherein the PET is semi-crystalline or crystalline. In someembodiments, moisture may be added to preform 18 during the moldingprocess to produce container 10 wherein the PET is semi-crystalline orcrystalline.

In some embodiments, the method is adapted in one or more of the waysdiscussed above to produce a container that has a crystallinity betweenabout 5% and about 40%. In some embodiments, the method is adapted inone or more of the ways discussed above to produce a container that hasa crystallinity of about 10%. In some embodiments, the method is adaptedin one or more of the ways discussed above to produce a container thathas a crystallinity between about 15% and about 20%. In someembodiments, the method is adapted in one or more of the ways discussedabove to produce a container that has a crystallinity between about 20%and about 25%. In some embodiments, the method is adapted in one or moreof the ways discussed above to produce a container that has acrystallinity between about 18% and about 30%. In some embodiments, themethod is adapted in one or more of the ways discussed above to producea container that has a crystallinity between about 20% and about 40%. Insome embodiments, the crystallinity of container 10 may be modified suchthat container 10 comprises layers that contain strength hardened PETwith the characteristics discussed above.

In one embodiment, shown in FIG. 6, preform 18 does not include discretelayers. Rather, top portion 25 consists of one material, such as, forexample, PET or virgin PET and bottom portion 35 comprises a materialwith at least one additive A, such as, for example, a passive scavengerand/or an active scavenger dispersed heterogeneously throughout thematerial in non-layered form. In other words, additive A is not in anyone defined region so that layers are not detectable. In someembodiments, additive A is one or more of the additives discussedherein. In some embodiments, additive A is dispersed erratically in thematerial. In some embodiments, the heterogeneous distribution ofadditive A provides different areas or regions R of preform 18. That is,preform 18 includes some regions R, such as, for example, region R1 thatdo not include additive A and other regions R, such as, for example,region R2 that include additive A. In some embodiments, regions R aredefined by a thickness of preform 18 that extends from an inner surface18A of preform to an outer surface 18B of preform 18.

During the molding process, the heterogeneous dispersion of additive Ain bottom portion 35 is also present in finished container 10, as shownin FIG. 8. In some embodiments, the additive A includes an oxygenscavenger, such as, for example, one or more of the oxygen scavengersdiscussed herein, wherein the oxygen scavenger is configured to decreasethe level of oxygen in container 10. That is, the oxygen scavenger willprevent or reduce the amount of oxygen that will be able to enter theinside 15 of container 10, hence extending the shelf life of any foodand/or beverage product within container 10. Indeed, the heterogeneousdispersion of additive A can form an undefinable barrier that preventsor reduces the ability of oxygen to move from the environmentsurrounding container 10 to the inside 15 of container 10. In theembodiments shown in FIGS. 6 and 10, steps S3-S9 are the same asdiscussed above with the other embodiments.

It will be understood that various modifications may be made to theembodiments disclosed herein. Therefore, the above description shouldnot be construed as limiting, but merely as exemplification of thevarious embodiments. Those skilled in the art will envision othermodifications within the scope and spirit of the claims appended hereto.

What is claimed is:
 1. A method for manufacturing a container, the method comprising the steps of: disposing a preform in a mold, the preform including opposite top and bottom sections, the top section including a flange, the bottom section being formed from an outer layer, an intermediate layer and an inner layer, the top section being formed from only one layer, the intermediate layer comprising an additive, the additive comprising an active oxygen scavenger; blow molding the preform into an intermediate article; and trimming the intermediate article to form a finished container, the active oxygen scavenger being present in an amount between about 0.1 wt. % and about 5.0 wt. % of the finished container.
 2. The method recited in claim 1, wherein the layer that forms the top section is free of the additive.
 3. The method recited in claim 1, wherein the outer layer is free of the additive, the inner layer is free of the additive, and the layer that forms the top section is free of the additive.
 4. The method recited in claim 1, further comprising forming the preform, wherein the preform is formed without a sprue.
 5. The method recited in claim 1, wherein the preform does not include a sprue when the preform is disposed in the mold.
 6. The method recited in claim 1, wherein the intermediate layer does not extend through the outer layer when the preform is disposed in the mold.
 7. The method recited in claim 1, wherein the intermediate layer does not extend through the outer layer or the inner layer when the preform is disposed in the mold.
 8. The method recited in claim 1, wherein the intermediate layer is positioned between the inner and outer layers along an entire length of the bottom portion.
 9. The method recited in claim 1, wherein the bottom portion comprises opposite first and second sidewalls and a bottom wall that extends from the first sidewall to the second sidewall, the bottom wall having the intermediate layer positioned between the inner and outer layers continuously from the first sidewall to the second sidewall.
 10. The method recited in claim 1, wherein a thickness of a wall of the preform is defined by the inner, outer and intermediate layers, the thickness having a midline equidistant between an outer surface of the outer layer and an inner surface of the inner layer, the wall having a first portion extending from the outer surface to the midline and a second portion extending from the inner surface to the midline, at least a portion of the intermediate layer being positioned in the second portion.
 11. The method recited in claim 1, wherein the intermediate layer has a thickness that is less than a thickness of at least one of the inner and outer layers.
 12. A method for manufacturing a container, the method comprising the steps of: disposing a preform in a mold, the preform including opposite top and bottom sections, the top section including a flange, the bottom section being formed from an outer layer, an intermediate layer and an inner layer, the top section being formed from only one layer; blow molding the preform into an intermediate article; and trimming the intermediate article to form a finished container, wherein the inner layer, the outer layer and the layer that forms the top section each comprise polyethylene terephythalate, and wherein the intermediate layer comprises an additive, the additive comprising an active oxygen scavenger, the active oxygen scavenger being present in an amount between about 0.1 wt. % and about 5.0 wt. % of the finished container.
 13. The method recited in claim 12, wherein the intermediate layer comprises polyethylene terephythalate and the additive.
 14. The method recited in claim 13, wherein the inner layer, the outer layer and the layer that forms the top section each consist of polyethylene terephythalate.
 15. The method recited in claim 12, wherein the intermediate layer consists of the additive.
 16. The method recited in claim 13, wherein the inner layer, the outer layer and the intermediate layer each have a uniform thickness.
 17. A method for manufacturing a container, the method comprising the steps of: disposing a preform in a mold, the preform including opposite top and bottom sections, the top section including a flange, the bottom section being formed from an outer layer, an intermediate layer and an inner layer, the top section being formed from only one layer; blow molding the preform into an intermediate article; and trimming the intermediate article to form a finished container, wherein a thickness of a wall of the preform is defined by the inner, outer and intermediate layers, the thickness having a midline equidistant between an outer surface of the outer layer and an inner surface of the inner layer, the wall having a first portion extending from the outer surface to the midline and a second portion extending from the inner surface to the midline, at least a portion of the intermediate layer being positioned in the second portion, wherein the intermediate layer comprises an active oxygen scavenger, wherein the inner layer, the outer layer and the layer that forms the top section each comprise polyethylene terephythalate and are free of the active oxygen scavenger, and wherein the active oxygen scavenger is present in an amount between about 0.1 wt. % and about 5.0 wt. % of the finished container.
 18. The method recited in claim 1, further comprising mounting the flange on the mold.
 19. The method recited in claim 1, wherein the additive further comprises a colorant.
 20. The method recited in claim 1, wherein the additive further comprises a passive oxygen scavenger. 